EP3964309A1 - Systèmes et procédés d'estimation de dosage de poudre dans des processus de fabrication additive - Google Patents

Systèmes et procédés d'estimation de dosage de poudre dans des processus de fabrication additive Download PDF

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Publication number
EP3964309A1
EP3964309A1 EP21190607.8A EP21190607A EP3964309A1 EP 3964309 A1 EP3964309 A1 EP 3964309A1 EP 21190607 A EP21190607 A EP 21190607A EP 3964309 A1 EP3964309 A1 EP 3964309A1
Authority
EP
European Patent Office
Prior art keywords
powder
dosing
component
pbf
pbf system
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21190607.8A
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German (de)
English (en)
Inventor
UGARTE Johnnattan Tennessee
JAYAWICKREMA Joanna Mechelle
ZHANG Xuefeng
HU Jun Zheng
VETCHA Kishore
VANAPALLI Veeraraju
DESROSIERS Andrew
FAIRMAN Ruben Egberto
LOZIER Ryan Antony
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General Electric Co
Original Assignee
General Electric Co
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Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Publication of EP3964309A1 publication Critical patent/EP3964309A1/fr
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/57—Metering means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/343—Metering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure relates generally to additive manufacturing and more particularly to systems and methods for estimating powder dosing for additive manufacturing processes, such as direct metal laser melting (DMLM) systems.
  • DMLM direct metal laser melting
  • PBF powder bed fusion
  • support structures may be utilized to anchor the component to a build platform and provide a thermally conductive pathway for heat to dissipate from the component.
  • PBF systems include direct metal laser melting (DMLM) systems, electron beam melting (EBM) systems, selective laser melting (SLM) systems, directed metal laser sintering (DMLS) systems, and selective laser sintering (SLS) systems. These PBF systems involve focusing an energy beam onto a bed of powder to melt or sinter sequential layers of powder to one another to form a component.
  • Typical PBF systems include a supply chamber, a build chamber, and an overflow collector.
  • powder is provided in the supply chamber based on the component to be printed.
  • the supply chamber also generally includes a piston which elevates a powder floor during operation of the system. As the floor elevates, a portion of the powder is forced out of the supply chamber and into the build chamber.
  • a recoater such as a roller or a blade, pushes some of the powder onto a build platform. The recoater sequentially distributes thin layers of powder onto the build platform.
  • An energy source directs an energy beam such as a laser or an electron beam onto the thin layer of powder to melt or fuse the sequential layers of powder.
  • the powder is fully melted, with respective layers being melted or re-melted with respective passes of the energy beam.
  • layers of powder are sintered, fusing particles of powder with one another generally without reaching the melting point of the powder.
  • the system does not regulate the powder being added to the build chamber. Further, in such systems, required powder dosing varies from layer to layer as a function of cross-sectional area, part perimeter, material properties, and laser scan parameters.
  • Current methods for powder dosing rely on user observation, and dosing regulation as the build progresses - for tall or complicated builds.
  • high dosing of the powder produces waste in the overflow collector and can result in running out of powder before build is complete.
  • the wasted powder in the overflow collector cannot be reused.
  • low dosing can result in short feeds, part defects, and/or build crashes. Accordingly, for conventional methods, overdosing is the preferred method to prevent short feeds.
  • the present disclosure is directed to a method for forming a component, such as an aircraft component.
  • the method includes estimating a dosing plan for powder of a powder bed fusion (PBF) system (such as a direct metal laser melting (DMLM) system) needed to form the component.
  • the dosing plan includes powder dosing requirements needed per layer to form the component.
  • the method includes providing the dosing plan to a controller of the PBF system. Further, the method includes regulating the powder being supplied to a build chamber of the PBF system from a supply chamber of the PBF system based on the dosing plan. In addition, the method includes additively manufacturing the component onto a build platform via the PBF system using the powder in the build chamber.
  • PBF powder bed fusion
  • DMLM direct metal laser melting
  • the present disclosure is directed to a powder bed fusion (PBF) system for forming a component.
  • the PBF system includes a build chamber having a build platform, a recoater, a supply chamber configured to receive an amount of powder based on the component to be formed, an energy source, and a controller.
  • the supply chamber includes a supply platform, such that, as the supply platform elevates, the powder is forced out of the supply chamber layer-by-layer and into the build chamber atop the build platform via the recoater.
  • the energy source includes an energy beam that is directed onto the powder in the build chamber to melt or fuse sequential layers of powder together to form the component.
  • the controller is configured to regulate the powder being supplied to the build chamber from the supply chamber of the PBF system based on a predetermined dosing plan stored therein, the dosing plan comprising powder dosing requirements needed per layer to form the component.
  • upstream and downstream refer to the relative direction with respect to fluid flow in a fluid pathway.
  • upstream refers to the direction from which the fluid flows
  • downstream refers to the direction to which the fluid flows.
  • top refers to the direction from which the fluid flows
  • downstream refers to the direction to which the fluid flows.
  • Approximating language is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems.
  • the present disclosure is directed to a method for estimating powder dosing/use needs on a layerwise basis for an additive manufacturing system and/or adjusting powder dosing layerwise based on that estimation. Accordingly, the present disclosure is more reliable than prior art systems that relied on user observation and dosing regulation as the build progresses.
  • the methods of the preset disclosure can predict, reduce, and ultimately eliminate the need for manual operator intervention. As such, the powder required to build a particular part can be better managed, thereby extending the use of the powder and build height capability.
  • scrap builds due to lack of powder to complete the build) are reduced and/or eliminated.
  • FIGS. 1 and 2 illustrate a schematic diagram of one embodiment of an additive manufacturing system 100 according the present disclosure.
  • the additive manufacturing system 100 may include, for example, a powder bed fusion (PBF) system, such as a direct metal laser melting (DMLM) system, an electron beam melting (EBM) system, a selective laser melting (SLM) system, a directed metal laser sintering (DMLS) system, or a selective laser sintering (SLS) system.
  • PPF powder bed fusion
  • DMLM direct metal laser melting
  • EBM electron beam melting
  • SLM selective laser melting
  • DMLS directed metal laser sintering
  • SLS selective laser sintering
  • the illustrated additive manufacturing system 100 includes a powder supply chamber 102 that contains a supply of powder material 104, and a build chamber 106 within which a component 108 may be additively manufactured in a layer-by-layer manner.
  • the component 108 may be an aircraft component.
  • the component 108 may be a component of a gas turbine engine.
  • the component 108 may be an airfoil separator or a heat exchanger for a gas turbine engine.
  • the component 108 may be any suitable part that can benefit from additive manufacturing technology.
  • the powder material 104 may include a metal or metal alloy, a plastic, a ceramic, and/or a composite.
  • a metal or metal alloy powder may include tungsten, aluminum, chromium, copper, cobalt, molybdenum, tantalum, titanium, nickel, and steel, and combinations thereof, as well as super alloys, such as austenitic nickel-chromium-based super alloys.
  • the powder supply chamber 102 includes a powder piston 110 that elevates a powder floor 112 during operation of the system 100. As the powder floor 112 elevates, a portion of the powder 104 is forced out of the powder supply chamber 102.
  • a recoater 114 such as a roller or a blade pushes some of the powder 104 across a work surface 116 and onto a build platform 118. The recoater 114 sequentially distributes thin layers of powder 104 onto the build platform 118.
  • An energy source 120 directs an energy beam 122 such as a laser or an electron beam onto the thin layer of powder 104 to melt or fuse the sequential layers of powder 104.
  • the powder 104 is fully melted, with respective layers being melted or re-melted with respective passes of the energy beam 122.
  • layers of powder 104 are sintered, fusing particles of powder 104 with one another generally without reaching the melting point of the powder 104.
  • the energy source 120 may be controlled via a controller 130 for controlling the various components of the system 100.
  • a scanner 124 may be communicatively coupled with the controller 130 for controlling the path of the beam to melt or fuse only the portions of the layer of powder 104 that are to become part of the component 108.
  • the first layer or series of layers of powder 104 are typically melted or fused to the build platform 118, and then sequential layers of powder 104 are melted or fused to one another to additively manufacture the component 108.
  • the first several layers of powder 104 that become melted or fused to the build platform 118 define a support structure 126 for the component 108. As sequential layers of powder 104 are melted or fused to one another, as shown in FIG.
  • a build piston 128 gradually lowers the build platform 118 to make room for the recoater 114 to distribute sequential layers of powder 104. Sequential layers of powder 104 may be melted or fused to the component 108 until a completed component 108 has been fabricated (as shown in FIG. 2 ).
  • the support structure 126 generally provides a surface to which sequential layers of powder 104 may be melted or fused, while holding the sequential layers of melted or fused powder in position while resisting residual stresses caused by rapid changes in temperature as the energy beam 122 melts or fuses the sequential layers of powder 104.
  • the support structure 126 also provides a thermally conductive pathway to dissipate heat generated by the energy beam 122.
  • a support structure 126 may be fabricated in the same manner as the component 108.
  • the same powder 104 may be used to fabricate the support structure 126 and the component 108.
  • a different powder 104 may be used for the support structure 126 and the component 108.
  • the energy beam 122 When forming the support structure 126, the energy beam 122 typically melts or sinters the top surface of the build platform 118 together with the first few layers of powder 104 to securely weld (e.g., melt or fuse) the support structure 126 to the build platform 118. After the component 108 has been fabricated, the support structure 126 may be removed from the component 108 in post-fabrication processes.
  • the PBF system 100 may also include an overflow collector 132 for collecting excess powder from the build chamber 106.
  • the recoater 114 is moveable across the supply chamber 102, the build chamber 106, and the overflow collector 132 to move the excess powder to the overflow collector 132.
  • the controller 130 may be further configured to regulate the powder 104 being supplied to the build chamber 106 from the supply chamber 102 of the PBF system 100 based on a predetermined dosing plan stored therein, which will be discussed in more detail herein.
  • the controller 130 may be communicatively coupled to any of the components of the system 100 in order to control the operation of such components.
  • the controller 130 may include a computer or other suitable processing unit.
  • the controller 130 may include suitable computer-readable instructions that, when implemented, configure the controller 130 to perform various different functions, such as receiving, transmitting and/or executing control signals.
  • the controller 130 may include one or more processor(s) 134 and associated memory device(s) 136 configured to perform a variety of computer-implemented functions (e.g., performing the methods, steps, calculations and the like disclosed herein).
  • processor refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits.
  • PLC programmable logic controller
  • the memory device(s) 136 may generally comprise memory element(s) including, but are not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and/or other suitable memory elements.
  • the controller 130 may also include a communications module 138 to facilitate communications between the controller 130 and the various components of the system 100.
  • the communications module 138 may include a sensor interface 140 (e.g., one or more analog-to-digital converters) to permit the signals transmitted by one or more sensors 142, 144 to be converted into signals that can be understood and processed by the controller 130.
  • the sensors 142, 144 may be communicatively coupled to the communications module 138 using any suitable means.
  • the sensors 142, 144 are coupled to the sensor interface 138 via a wired connection.
  • the sensors 142, 144 may be coupled to the sensor interface 64 via a wireless connection, such as by using any suitable wireless communications protocol known in the art.
  • the processor 134 may be configured to receive one or more signals from the sensors 142, 144.
  • FIG. 4 a flow chart 200 of a method for forming a component, such as an aircraft component, according to the present disclosure is illustrated.
  • the method 200 will be described herein with reference to the component 108 and additive manufacturing system 100 of FIGS. 1 and 2 .
  • the disclosed method 200 may be implemented with additive manufacturing systems having any other suitable configurations.
  • FIG. 4 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement.
  • steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.
  • the method 200 may include estimating a dosing plan for powder of the PBF system 100 (such as a DMLM system described herein) needed to form the component.
  • the dosing plan may include powder dosing requirements needed per layer to form the component.
  • the powder dosing requirements may be predetermined.
  • the controller 130 may estimate the dosing plan for the powder of the PBF system 100 by dividing an exposure area of the component into one or more zones, as shown via the dotted lines in FIG. 8 .
  • Such zone(s) may be associated with various parameters, such as a powder packing factor, a part orientation, a recoater contact, and/or build time productivity.
  • FIG. 8 particularly illustrates various zones being equally-impacted (left image) and heavily impacting (right image).
  • the controller 130 can determine a variance of the exposure area across the one or more zones, e.g. via an algorithm stored in the controller 130. Further, the controller 130 can minimize the variance of the exposure area across the zone(s) so as to equalize a power requirement across the build platform 118.
  • the algorithm can be combined with other system algorithms that rank the packing and orientation from the recoater contact, build time productivity, etc., to provide a holistic ranking for the packing and orientation.
  • the controller 130 may estimate the dosing plan for the powder of the PBF system 100 by receiving one or more inputs, e.g. relating to part geometry and a material type of the powder, calculating a shrinkage factor of the powder in a melted state, splitting the layers into a grid of pixels to determine which pixels require an amount of powder above a certain threshold and generating the dosing plan based on the shrink factor and the grid of pixels which may include an additional dosing factor to account for powder that may be lost to the areas surrounding the build box.
  • FIG. 7 illustrates a simplified pixel diagram of one layer of the component in which certain pixels need more powder (as represented via shaded boxes) than others (as represented by white boxes).
  • the dosing plan may be estimated by pre-determining a volume V of each layer of the component 108 (using the length 1, width w, and the thickness t), determining a perimeter P of each layer of the component 108, and estimating the powder dosing requirements of the dosing plan as a function of the volume V and the perimeter P.
  • the method 100 may include updating the powder dosing requirements in real-time as a function of geometry of the component 108.
  • the dosing plan may be estimated by adding an additional powder margin A ⁇ to the powder dosing requirements of the dosing plan.
  • the additional powder margin A ⁇ may account for an area around and between the build platform 126 and the supply chamber 102 or the overflow collector 132 of the PBF system 100.
  • the additional powder margin A ⁇ may account for melted powder having a lesser volume than powder particles.
  • the method 200 may include determining at least one of a shrinkage factor or a compaction level for the powder based on a powder type and estimating the powder dosing requirements of the dosing plan as a function of the shrinkage factor and/or the compaction level.
  • the method 200 may include providing the dosing plan to a controller of the PBF system 100. As shown at (206), the method 200 may include regulating the powder being supplied to the build chamber 106 of the PBF system 100 from the supply chamber 102 based on the dosing plan. In several embodiments, the method 200 may include automating, via the controller 130 of the PBF system 100, dosing level changes layer-by-layer. Referring still to FIG. 3 , as shown at (208), the method 200 may include additively manufacturing the component 108 onto the build platform 118 via the PBF system 100 using the powder 104 in the build chamber.
EP21190607.8A 2020-09-03 2021-08-10 Systèmes et procédés d'estimation de dosage de poudre dans des processus de fabrication additive Pending EP3964309A1 (fr)

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US17/011,325 US11638959B2 (en) 2020-09-03 2020-09-03 Systems and methods for estimating powder dosing in additive manufacturing processes

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EP3964309A1 true EP3964309A1 (fr) 2022-03-09

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US (2) US11638959B2 (fr)
EP (1) EP3964309A1 (fr)
JP (1) JP7252290B2 (fr)
CN (1) CN114131041A (fr)

Citations (1)

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US20200247059A1 (en) * 2015-11-30 2020-08-06 Eos Gmbh Electro Optical Systems Method and Device for Ascertaining Required Construction Material

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US11638959B2 (en) 2023-05-02

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